Process of making felted containers



Jan. 2, 1962 D. M. HAWLEY 3,0

PROCESS OF MAKING FELTED CONTAINERS Filed Aug. 12, 1957 2 Sheets-Sheet 1FIG. I

will.

Jan. 2, 1962 D. M. HAWLEY PROCESS OF MAKING FELTED CONTAINERS 2Sheets-Sheet 2 Filed Aug. 12, 1957 INVENTOR: DON M. HAWLEY BY gffasqueeze rolls.

with each pair of rolls.

United States Patent This invention, in general, relates to a continuousprocess for making blanks to be folded into cartons.

The process of the instant invention is designed to produce paperboardblanks having scored lines therein,

which blanks may be subsequently foldled along the scored lines intocontainers or cartons. The flat cellulosic fibrous felt may be made onany type of paper or pulp machine capable of making a continuous felt ofthe desired thickness. The quality of the cellulosic pulp may be variedwidely, ranging from 100% scrap mate rials, such as newspaper andcorrugated box scrap, to high quality wood pulpdepending upon thequality of the carton or container desired.

Broadlyspeaking, the invention is concerned with the continuousformation of a continuous, heavy felt of fibrous pulp into a container.The felt or heavy sheet is formed on a paper-making machine such as acylinder machine or a Fourdrinier machine. After the felt leaves thefelt-forming machine, it is passed through a series of These rolls arepreferably arranged in pairs, and as the felt passes through the seriesof rolls the pressure exerted on the felt is increased progressively Thefunction of the pressure rolls is to squeeze out a considerable portionof the water in the felt. The lower rolls are usually vacuum rolls,i.e., hollow rolls having a foraminous cylindrical surface. A vacuum isapplied to the roll from within to assist in removing the water whichgathers at the nip of the rolls as the sheet is being squeezed. Thevacuum rolls are necessary, for otherwise the large amount of Watersqueezed out accumulates in the nip and weakens the sheet so that itbreaks.

The squeezed, wet felt thereafter is passed through one or more pairs ofscoring rolls, which are rolEs having rods or bras forming protrusionson the cylindrical surface to score the sheet in the desired pattern.The scoring provided by the rolls determines the ultimate type of boxwhich may be shaped from the blank produced by the scoring. Thecircumference of the rolls may be changed to produce various sizes ofbox-the size of the box being dependent upon the circumference of theroll.

After the scoring operation the sheet is passed through a drier andthereafter cut into scored blanks by an automatic cutter.

It is an object of the present invention to provide a continuous processfor the manufacture of flat, scored paperboard blanks for cartons orcontainers wherein the formation of the paperboard sheet and the scoringof the sheet are carried out in a continuous operation.

Another object is to provide a continuous process in the manufacture ofpaperboard blanks for cartons or containers in which the scoring is doneon the wet paperboard sheet.

scribed. Other objects will appear hereinafter.

The invention will be further described in conjunction with thedrawings, whereing FIG. 1 is a perspective view of a series of apparatusadapted to carry out the process of this invention;

FIG. 2 is a more detailed view of two of the roller pairs of FIG. 1;

FIG. 3 is a perspective view of a scored, paperboard blank adapted to beproduced by the process illustrated in FIG. 1;

FIGS. 4 and 5 are perspective views of cartons or containers which maybe made from the blank of FIG. 3;

FIG. 6 is a perspective view of a carton segment or panel provided withribs for improving the rigidity thereof; and

FIGS. 7 and 8 are partial, perspective views of cartons produced by theprocess of the invention and additionally illustrate devices for holdingthe covers closed.

The process of the invention is illustrated in FIGS. 1 and 2 in whichthe fibrous felt It is formed from cellulosic pulp extruded from theheadbox 12 onto the continuous, moving wire screen 14 of a Fourdriniermachine. The screen is supported by a series of rolls known as tablerolls 16. On the underside of the Fourdrinier screen 14 are suctionboxes 18 for removing water from the felt, and a dandy roll 20 isprovided to even out the upper surface of the felt. A suction couch rollis provided at 22. The Fourdrinier machine has been described onlysketchily because the details of the machine are well known and do notcomprise a part of the instant invention.

After the felt leaves the Fourdrinier machine, it passes through aseries of pressure rolls comprising pairs of upper rolls 24 and lowerrolls 26. The lower rolls 26 are vacuum rolls which are illustrated infurther detail in FIG. 2. The vacuum roll comprises a forarninous,cylindrical, hollow body 38 upon which is supported a wire screen 40.The vacuum is applied to the interior of the roll. The function of thevacuum roll is to remove water which is squeezed out of the felt as itpasses between the pressure rolls.

After the pressure rolls, the squeezed, wet felt is passed between aseries of scoring rolls 28, 30. The upper scoring rolls 28 haveprotrusions formed by bars or rods 323436 on the surface of the rolls28. These protrusions impart the scoring to the felt to provide foldlines for the subsequent shaping of the container or carton. The bars orrods 32-3436 may be positioned on the rolls to provide the desiredpattern of score lines. in the embodiment illustrated, the diagonal bars32 provide diagonal score lines, the longitudinal bars 34 providetransverse score lines, and the circumferential protrusions 36 providelongitudinal score lines on the felt.

The scored felt is then passed through a drying oven 42 where the sheetis dried. After the sheet emerges from the drying oven 42, it is cutinto the carton blanks by an automatic cutter 44 mounted on the cuttingand stacking table 46. The cut blanks, under the urging of the movementof the sheet, fall onto the stacking support 5% and thus form a stack ofcut blanks 43.

FIGS. 3-7 illustrate blanks and cartons which may be manufacturedaccording to the process previously described. In FIG. 3, the blankcomprises a paperboard sheet 60 having score lines 62 defining the foldbetween the bottom panel 76 and the four side walls 78. Corner scorelines 64 define the corner fold lines for the carton. At each corner,defined by the corner score lines 64, a score or slit 66 is providedwhich diagonally cuts across the corner formed by the corner score lines64.

If a cover is desired, a score line 68 is provided to define the foldbetween a side wall 78 and the cover panel 84. The score line 68' isextended to the edges of the blank by score lines 70 which are slitbefore the box is assembled. Score lines 72 define the junction betweenthe cover panel 84 and the side flaps of the cover 86. An additionalscore line 74 defines the junction between the cover panel 84 and thecover front flap 38. If desired, the corner of the front flap may be cutout along the line 74 and the extension of the score lines 72.

FIGS. 4-7 illustrate cartons which can be formed from the carton blankof FIG. 2. The carton shown in FIG. 4 is especially useful where waterleakage is to be avoided, because this container has no slits or seamsthrough which the water can leak as long as the carton remains upright.It is assembled by folding the sides 78 vertically about the bottompanel 76. The diagonal scores 66 are folded inwardly toward the centerof the box to form triangular folds 80. The triangular fold 80 aresecured to the side panels 78 of the box by staples 82. or othersuitable fastening means and thus reenforce the side panels. The cover84 may be omitted if desired, but if such cover is provided it is formedby slitting the score line 70 and also the score line 75. The side flaps86 of the cover are then bent downwardly along score lines 72 and thefront flap 88 is bent downwardly along score line 74. The portion of thefront flap 88 extending beyond the score line 72 at each end may be cutoff to provide a front fiap 88 coextensive with the width of the cover84.

The carton of FIG. is assembled from a similar blank to that illustratedin FIG. 3 with the cover portion omitted. Instead of folding thediagonal scores 66, each diagonal score is slit up to the corner of thebottom panel. Thus, the carton in FIG. 5 comprises a rectangular bottompanel 90 and four regular trapezoidal, upstanding side panels 92, theright triangular end segments 94 of the trapezoidal sides being foldedand secured to alter nate sides of the adjacent side panels at thecorners of the box by suitable means such as staples 96.

FIG. 6 is an illustration of an insert 98 of a box, which provides abottom panel having ribs 100 for adding rigidity to the box. The ribs100 can be formed integrally and initially in the moving wet sheet bycircurnferential protrusionssimilar to the protrusions 36 on the rollersfor providing the score lines.

FIGS. 7 and 8 illustrate containers similar to the open container ofFIG. 5. However, the containers of FIGS. 7 and 8 have covers thereon.Like numerals have been used in FIGS. 7 and 8 to indicate like partsillustrated in FIG. 5, where applicable. In addition to the similarparts, the containers of FIGS. 7 and 8 have covers 102 hingedlyconnected to the rear side panel 92. The covers 102 have downwardlyfolded front flaps 104 which may have side tabs 106 extending therefrom.The cover in FIG. 7 is held closed by a fastening device 108 comprisingtwo straight legs 110-112 connected by a bight 114. The straight leg 110extends through aligned apertures in the rear panel of the box and thefront panel of the box and the flap 104 of the cover 102 to hold the lidagainst opening. The locking member 108 is secured on the box by ahook-shaped catch 116 which is a transverse extension of the leg 112 andbooks about the leg 110.

Another modification of a locking member is shown in FIG. 8 wherein atriangular-shaped locking member 120 has the hypotenuse leg 122extending through apertures in the front panel 92 and front flap 104 ofthe box and also through apertures in a side panel and cover side flap106 of the box. The remainder of the locking mem ber comprises legs 124and 126, the latter terminating in a hook-shaped catch 128 adapted tobook about the protruding end of the hypotenuse leg 122.

In the process and apparatus described the felt is relatively thick,preferably around inch to /2 inch in thickness. The screen or wire sideof the felt is relatively smooth. The grooves or recesses placed in thetop side of the felt by the scoring roll or rolls are relatively wide,being approximately the same width as the thickness of the felt. Thecontainer is preferably folded with the smooth or screen side outward.Although the fibers used are preferably cellulose, the inventioncontemplates the use of difierent types of fibers including, wood,cotton, linen, wool, ramie, jute, hemp, sisal, glass fibers, glassstrands, hennequen, caroa and/or asbestos.

In practicing the invention the placement of the scoring rolls issubject to variation. For example, the scoring rolls may be alternatedwith respect to the squeeze rolls.

The term thick as used herein means having a thickness which isrelatively greater than the ordinary thickness of paper or paperboard.This thickness, moreover, is preferably sufiicient to make the resultantcontainer relatively rigid or non-flexible. The web orfibrous felt fromwhich the container is formed is also relatively rigid or non-flexibleexcept for the recessed or grooved portions which are sufficientlyflexible to permit bending.

The invention is hereby claimed as follows:

l. A continuous process for making carton blanks comprising forming acontinuous, fibrous, thick felt from an aqueous slurry of cellulosicfibers on a felt-forming mechanism of a paper-making machine; passingthe continuous, fibrous felt, upon leaving said forming mechanism,through a series of pairs of squeeze rolls and'thereby squeezing waterfrom said felt, the pressure exerted by each pair of squeeze rolls beingprogressively greater; scoring in the squeezed, wet felt fold linesextending longitudinally of and laterally across the wet felt for thefolding of said blank into box form; and drying the scored, wet felt,all in one continuous operation.

2. A continuous process for making carton blanks comprising forming awet, continuous, thick, felted, fibrous, sheet from an aqueous slurry offibers on continuous felt-forming machine; pass-ing the wet, continuous,fibrous felt through a series of squeeze rolls, exerting pressure onsaid felt and removing water squeezed from said felt under pressure;passing the squeezed, wet felt through a further series of rolls andtherein scoring folding lines into said felt with raised portions onsaid rolls, thereby providing repeating sections, each having apredetermined, scored pattern on said felt for the folding of said blankinto box form, each section including a pair of parallel, longitudinal,scored fold lines and a pair of lateral, scored fold lines dividing eachsection into a rectangular center panel, four rectangular side panels ofan equal length with the corresponding side of the center panel and fourrectangular corner panels and also including diagonal, scored fold linesextending from the corners of said center panel to the diagonallyopposite corners of said corner panels; and drying the scored, wet felt.

3. A continuous process for making carton blanks comprising forming awet, continuous, thick, felted, fibrous, sheet from an aqueous slurry offibers on continuous felt-forming machine; passing the wet, continuous,fibrous felt through a series of squeeze rolls, exerting pressure onsaid felt and removing water squeezed from said felt under pressure;passing the squeezed, wet felt at a felt thickness of about A. to /2inch through a further 7 series of rolls and therein scoring foldinglines into said felt with raised portions on said rolls, therebyproviding repeating sections, each having a predetermined, scoredpattern on said felt for the folding of said blank into box form, eachsection including a pair of parallel, longitudinal, scored fold linesand a pair of lateral, scored fold lines dividing each section into arectangular center panel, four rectangular side panels of an equallength with the corresponding side of the center panel and fourrectangular corner panels; diagonally slitting the corner panels 5 6along a line between the corners of said center panel and 1,455,752Lucey May 15, 1923 the diagonally opposite corners of said corner panelsand 1,530,677 Klund et al Mar. 2 4, 1925 drying the scored, Wetfelt.1,973,339 Fleming Sept. 11, 1934 2,272,703 Haegele Feb. 10, 1942References Cited in the file of this patent 5 2,402,966 Linzell July 2,1946 UNITED STATES PATENTS ,6 9 Buttery y 1954 711 815 B hr d O 21 19022,792,165 Thompson May 14, 1957 e 7 en ct. 717,799 Behfend Jan. 6, 1903FOREIGN PATENTS 1,414,549 Cleary May 2, 1922 198,781 Great Britain June11, 1923 UNITED STATES PATENT OFFICE CERTIFICATE. OF CORRECTION PatentNo, $015,603 v I January 2 1962 Don Milligan Hawley' It is herebycertified that error appears in the above numbered patent requiringcorrection and that the said Letters Patent should read as correctedbelow.

Column 1, line 13, f0r"'foldbed" read folded line 43, for "bras" readbars Signed and sealed this 19th day of Junl962q (SEAL) Attest:

ERNEST w. SWIDER DAVID LADD Attesting Officer Commissioner of Patents

1. A CONTINNOUS PROCESS FOR MAKING CARTON BLANKS COMPRISING FORMING ACONTINUOUS, FIBROUS, THICK FELT FROM AN AQUEOUS SLURRY OF CELULOSICFIBERS ON A FELT-FORMING MECHANISM OF A PAPER-MAKING MACHINE; PASSINGTHE CONTINUOUS, FIBROUS FELT, UPON LEAVING SAID FORMING MECHANISM,THROUGH A SERIES OF PAIRS OF SQUEEZE ROLLS AND THEREBY SQUEEZING WATERFROM SAID FELT, THE PRESSURE EXERTED BY EACH PAIR OF SQUEEZE ROLLS BEINGPROGRESSIVELY GREATER SCORING IN THE SQUEEZED, WET FELT FOLD LINESEXTENDING LONGITUDINALLY OF AND LATERALLY ACROSS THE WET FELT FOR THEFOLDING OF SAID BLANK INTO BOX FORM; AND DRYING THE SCORED, WET FELT,ALL IN ONE CONTINUOUS OPERATION.